Soundproofing structure

Abstract

To provide a sound-insulating structure capable of obtaining a high sound-insulating effect even when a concave-convex structure body having a concave-convex structure is provided to a member having a large rigidity. A sound-insulating structure having: a soft member which, in a compression test performed using a compression testing machine, has a load applied to give a deformation rate of 4% of 160 kPa or less; a body to be bonded to which the soft member is provided; and a concave-convex sheet member having a concave-convex structure including a sheet portion and a convex portion provided on a surface of the sheet portion, wherein the soft member is provided in a manner arranged between the body to be bonded and the concave-convex sheet member.

Description

Technical Field

[0001] The present invention relates to a sound insulation structure having a tab member, a flexible member, and an adhesive body having the flexible member disposed thereon. Background Technology

[0002] In buildings such as residential buildings, office buildings, and hotels, there is a requirement to isolate outdoor noise from vehicles, railways, airplanes, or ships, as well as equipment noise and human voices generated inside the building, to achieve a quiet environment suitable for the intended use of the room. Furthermore, in vehicles such as cars, railways, airplanes, and ships, it is necessary to reduce indoor noise in order to isolate wind noise and engine noise and provide a quiet and comfortable space for passengers. Therefore, research and development of sound insulation methods—means to isolate the propagation of noise and vibration from the outside to the inside, or from the outside of a vehicle to the inside—has been steadily advancing. In recent years, the need for high-rise buildings, improved energy efficiency of transportation vehicles, and greater design freedom for buildings, vehicles, and equipment has led to a demand for sound insulation components capable of handling even complex shapes.

[0003] In the past, improvements have been made to the structure of sound insulation components, especially sheet-like components, to enhance their sound insulation performance. For example, methods are known to include combining multiple rigid flat materials such as gypsum board, concrete, steel plate, glass plate, or resin board (Patent Document 1); methods to form a hollow double-walled structure or a hollow triple-walled structure using gypsum board or the like (Patent Document 2); methods to combine flat materials with multiple independent pile-like protrusions (Patent Document 3); and methods to combine sound-absorbing materials in addition to flat materials and multiple independent pile-like protrusions (Patent Document 4).

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2013-231316

[0007] Patent Document 2: Japanese Patent Application Publication No. 2017-227109

[0008] Patent Document 3: International Publication No. 2017 / 135409

[0009] Patent Document 4: Japanese Patent Application Publication No. 2000-265593 Summary of the Invention

[0010] The problem that the invention aims to solve

[0011] Among the aforementioned conventional sound insulation components, the sound insulation components described in Patent Documents 3 and 4 are known to be sound insulation components having a rubber elastic sheet and cylindrical protrusions arranged in multiple rows on the surface of the sheet. The protrusions resonate in response to the incident sound, thereby performing their function and achieving sound insulation and vibration reduction performance exceeding the law of mass.

[0012] In recent years, precision instruments and home appliances have been required to be equipped with the function of isolating low-frequency sound and vibration emitted by the instruments during use. In order to meet this requirement, the sound insulation components with elastic sheets and cylindrical protrusions have been studied to improve their shielding performance by adjusting the material and size of the protrusions.

[0013] However, in order to improve the sound insulation effect in the low frequency band, it is necessary to increase the size of the columnar protrusion or to introduce counterweights into the protrusion to make it heavier. The sound insulation component will inevitably become thick-walled, resulting in larger size and increased weight, which cannot meet the requirements of shielding low frequency sound in small and lightweight instruments.

[0014] Various studies have been conducted, resulting in the development of a compact embossed sheet: by arranging multiple linear protrusions in a row along the same direction on a substrate with higher rigidity than conventional sound insulation components, high sound insulation performance in the low-frequency band can be achieved without increasing the height of the protruding parts on the substrate. It is speculated that with this configuration, the protrusions function as local (preferably local and periodic) rigidity and mass when sound is incident, exciting vibration modes corresponding to the distance between the protrusions and the substrate. The substrate vibrates in response to the incident sound, thereby increasing the sound insulation strength of the embossed sheet. Furthermore, by designing the shape of the protrusions on the substrate, the thickness of the substrate, etc., the sound insulation band can be freely adjusted.

[0015] However, when using such a textured sheet that utilizes the vibration of the substrate portion as a sound insulation component, if the substrate portion is directly placed on a rigid metal component or other structure, and sound waves without sufficient sound pressure are incident on the textured sheet, the substrate portion cannot vibrate, resulting in reduced sound insulation performance. Therefore, its application is limited. That is, in the component described in Patent Document 4, if the sound-absorbing material is rigid, the sound-absorbing material is thick, and sound waves without sufficient sound pressure are incident on the textured sheet, the sound insulation effect originating from the textured sheet will disappear.

[0016] The present invention was made in view of the above-mentioned problems, and its objective is to provide a sound insulation structure that can achieve a high sound insulation effect even when the concave-convex structure with concave-convex structure is provided on a rigid component.

[0017] Solution for solving the problem

[0018] To address the aforementioned problems, the inventors conducted in-depth research on the construction of a sound-insulating structure using a convex-concave plate member with a vibration mode effective for sound insulation in the substrate. The results showed that by combining the convex-concave plate member with a flexible and easily deformable member to form a convex-concave structure, and considering the position of the convex-concave plate member relative to the sound source, a sound insulation effect originating from the vibration of the convex-concave plate member's plate portion is exhibited even in heavy, rigid components such as metal. Specifically, it was found that when the convex-concave plate member, the flexible member, and the bonded body for mounting the flexible member are sequentially stacked relative to the direction of sound incidence, high sound insulation is exhibited in the sound-insulating band of the convex-concave plate member, thereby solving the aforementioned problems.

[0019] That is, the main idea of ​​this invention is as follows.

[0020] [1] A sound insulation structure, comprising:

[0021] For soft components, in compression tests conducted using a compression testing machine, a load of 4% or less is applied with a deformation rate of 160 kPa or less;

[0022] The bonded body, wherein the flexible member is disposed; and

[0023] The concave-convex plate component has a concave-convex structure.

[0024] The flexible member is disposed between the bonded body and the tab member.

[0025] [2] According to the sound insulation structure described in [1], the concave-convex structure has a sheet portion and a protrusion disposed on the surface of the sheet portion.

[0026] The weight ratio of the protrusion to the sheet, expressed as (weight of the protrusion / weight of the sheet), is 0.7 or more.

[0027] [3] According to the sound insulation structure described in [2], there is an adhesive layer between the convex and concave sheet members and the flexible members.

[0028] [4] The sound insulation structure according to any one of [2] or [3], wherein the areal density of the sheet portion is 2.5 kg / m³. 2 the following.

[0029] [5] The sound insulation structure according to any one of [2] to [4], wherein the density of the protrusion is 100 kg / m³. 3 above.

[0030] [6] The sound insulation structure according to any one of [2] to [5], wherein the height of the protrusion is 0.1 mm or more.

[0031] [7] The sound insulation structure according to any one of [2] to [6], wherein the number ratio of the protrusions is 1,000 to 10,000 per m. 2 .

[0032] [8] The sound insulation structure according to any one of [2] to [7], wherein the load imparting a deformation rate of 4% in the compression test performed by the compression testing machine is 0.15 kPa or more.

[0033] [9] The sound insulation structure according to any one of [2] to [8], wherein the weight ratio of the convex portion to the sheet portion of the concave-convex sheet member, expressed as (weight of the convex portion / weight of the sheet portion), is 5 or less, and,

[0034] In the compression test conducted using a compression testing machine, the soft component is subjected to a load of 10 kPa or less with a deformation rate of 4%.

[0035]

[10] The sound insulation structure according to any one of [2] to [9], wherein the concave-convex structure of the concave-convex sheet member is disposed on the side of the flexible member or the opposite side thereof.

[0036]

[11] The sound insulation structure according to any one of [2] to

[10] is used with a sound source, and the tab member is disposed with the side facing the sound source.

[0037]

[12] The sound insulation structure according to any one of [2] to

[11] satisfies the conditions shown in the following formulas (A) to (C).

[0038] (TL1-TL2)-(TL3-TL4)>3dB...(A)

[0039] TL1-TL2>0dB...(B)

[0040] TL3-TL4>0dB...(C)

[0041] TL1 (dB): Sound transmission loss of the sound insulation structure when the side of the convex-concave tab member faces the sound source.

[0042] TL2 (dB): The sound transmission loss of a sound insulation structure when the uneven sheet is replaced with a flat sheet of the same mass and area, under the condition of TL1.

[0043] TL3 (dB): The sound transmittance of a sound insulation structure when the bonded side faces the sound source.

[0044] TL4 (dB): The sound transmission loss of a sound insulation structure when the uneven sheet is replaced with a flat sheet of the same mass and area, under the condition of TL3.

[0045] TL1 and TL2 are the acoustic transmission losses at the frequencies where TL1-TL2 are at their maximum, and TL3 and TL4 are the acoustic transmission losses at the frequencies where TL3-TL4 are at their maximum.

[0046]

[13] The sound insulation structure according to any one of [2] to

[12] , wherein the convex-concave sheet member has a sheet portion and a protrusion protruding linearly on the sheet portion, and the convex-concave unit shape having the protrusion and the concave portion along the protrusion is repeatedly arranged on the sheet portion in one or two directions.

[0047]

[14] The sound insulation structure according to any one of [2] to

[13] , wherein the soft component is a non-woven fabric.

[0048]

[15] The sound insulation structure according to any one of [2] to

[13] , wherein the soft component is a foam.

[0049]

[16] A sound insulation sheet, comprising:

[0050] A convex-concave sheet member having a convex-concave structure, wherein the convex-concave structure is provided with a sheet portion and a plurality of protrusions disposed on the surface of the sheet portion; and

[0051] A flexible component, which is disposed on the concave-convex sheet component,

[0052] In the compression test conducted using a compression testing machine, the soft component was subjected to a load of 4% deformation rate of less than 160 kPa.

[0053] The weight ratio of the convex portion to the plate portion of the said convex-concave plate member, expressed as (weight of the convex portion / weight of the plate portion), is 0.7 or more.

[0054] Invention Effects

[0055] According to the present invention, a sound insulation structure can be provided that achieves high sound insulation performance even when the concave-convex structure with concave-convex structure is provided on a rigid component. Attached Figure Description

[0056] Figure 1 This is a schematic perspective view of one embodiment of the convex-concave sheet member of the present invention.

[0057] Figure 2 yes Figure 1 A schematic cross-sectional view of the convex and concave sheet component.

[0058] Figure 3 This is a schematic perspective view of one embodiment of the convex-concave sheet member of the present invention.

[0059] Figure 4 This is a schematic perspective view of one embodiment of the convex-concave sheet member of the present invention.

[0060] Figure 5 This is a schematic perspective view of one embodiment of the convex-concave sheet member of the present invention.

[0061] Figure 6 This is a schematic perspective view of one embodiment of the convex-concave sheet member of the present invention.

[0062] Figure 7 This is a schematic perspective view of one embodiment of the convex-concave sheet member of the present invention.

[0063] Figure 8 This is a schematic perspective view of one embodiment of the convex-concave sheet member of the present invention.

[0064] Figure 9 This is a schematic cross-sectional view of one embodiment of the sound insulation structure of the present invention.

[0065] Figure 10 This is a schematic cross-sectional view of one embodiment of the sound insulation structure of the present invention.

[0066] Figure 11 This is a schematic diagram showing the cut-off end face of an example of a mold used to manufacture a convex-concave component.

[0067] Figure 12 It is used to illustrate its use. Figure 13 A diagram illustrating the process of manufacturing convex and concave sheet components using molds.

[0068] Figure 13 (A) is a schematic view of a cylindrical mold, and (B) is a diagram illustrating the process of manufacturing a tab component using the mold.

[0069] Figure 14 This is a schematic cross-sectional view of one embodiment of the sound insulation structure of the present invention.

[0070] Figure 15 It is a graph showing the relationship between the peak value of the transmission loss difference and the weight ratio of the protrusion weight to the sheet weight in shape models 1 to 41, according to the mass law. Detailed Implementation

[0071] The present invention will now be described in detail. The following description is only one example (representative example) of the invention, and the invention is not limited thereto. Furthermore, the present invention can be implemented with any modifications without departing from its spirit.

[0072] It should be noted that the references to “~” in this specification indicate a range including the numbers preceding and following them.

[0073] In this specification, "multiple" means 2 or more.

[0074] <Sound insulation structure>

[0075] The sound insulation structure (also simply referred to as "sound insulation structure") according to embodiments of the present invention is a sound insulation structure having the following characteristics:

[0076] For soft components, in compression tests conducted using a compression testing machine, a load of 4% or less is applied with a deformation rate of 160 kPa or less;

[0077] The bonded body, which is used to provide the aforementioned flexible component; and

[0078] The concave-convex tab component has a concave-convex structure.

[0079] The flexible member is disposed between the bonded body and the tab member. Although the above-described sound insulation structure is simple in structure, it ensures high sound insulation performance, thus preventing large-scale construction. Furthermore, the tabs disposed on the flexible member experience minimal vibration resistance from the contacting member, thus achieving high sound insulation even for low sound pressure levels.

[0080] Furthermore, when the aforementioned sound insulation structure is used with a sound source, a configuration where the concave-convex plate member side faces the sound source achieves a higher sound insulation effect compared to a configuration where the bonded body side faces the sound source. This is believed to be because when a sound wave with a higher sound pressure level is incident on the concave-convex plate member, the plate portion vibrates effectively.

[0081] Furthermore, by adjusting the shape of the protrusions, the distance between the protrusions, and the thickness of the sheet, the frequency of sound insulation can be adjusted.

[0082] It should be noted that, in this specification, as described below, a soft member refers to a member subjected to a load of 160 kPa or less with a deformation rate of 4% in a compression test.

[0083] In addition, in this instruction manual, mass and weight have the same meaning, and mass can also be replaced with weight.

[0084] Hereinafter, various embodiments of the present invention will be described with reference to the accompanying drawings. It should be noted that the following embodiments are illustrative of the present invention, and the present invention is not limited to these embodiments.

[0085] [Anterior and posterior plate components]

[0086] (The composition of the convex and concave plate components)

[0087] Figure 1 and Figure 2 These are a schematic perspective view and a schematic cross-sectional view of the concave-convex sheet component 1, respectively. Figure 9 This is a schematic cross-sectional view of the sound insulation structure of this embodiment. The convex-concave sheet member 1 shown in the figure has a convex-concave structure 3. Specifically, it is a convex-concave structure with a sheet portion 2 and a protrusion 5 provided on the surface of the sheet portion. In addition, the convex-concave structure 3 can be provided on the side of the flexible member or the opposite side. More specifically, it can be formed as follows: a convex-concave structure 3 is provided on the side 2a of the sheet portion 2 (the side opposite to the side of the flexible member) with multiple rows of protrusions 5 extending linearly between the opposite long sides of the sheet portion 2. However, it can also be formed as follows: the convex-concave structure is provided on the side 2b of the sheet portion opposite to the side 2a (the side of the flexible member). In addition, it can also be formed as follows: the convex-concave structure is provided on both sides. The concave-convex structure 3 is formed by repeatedly arranging a convex portion 5 extending linearly on the surface of the sheet portion 2 and a concave portion 6 adjacent to the convex portion 5 as a flat portion as a concave-convex unit shape 4, and then arranging multiple of them between the relatively short sides of the sheet portion 2.

[0088] and, Figure 9 The sound insulation structure 7 shown is constructed by providing a flexible member 8 on the side 2b of the sheet portion 2 where the uneven structure 3 is not provided, and then providing an adhesive body 9 on the side 8b of the flexible member 8 where the uneven sheet member 1 is not provided.

[0089] In addition, the concave-convex structure 3 can be Figure 1 and Figure 2 The linear, uneven structure shown, or alternatively, it could be... Figure 6 The dotted, uneven structure shown.

[0090] In this embodiment, the sheet portion 2 is used to support the protrusions 5. By providing multiple protrusions 5 on the sheet portion 2, convex and concave portions are formed, thus forming a concave-convex structure 3. The material constituting the sheet portion 2 is not particularly limited as long as it can support the protrusions 5, and can be the same as or different from the material constituting the protrusions 5. However, from the viewpoint of supporting multiple protrusions 5, it is preferable to use a material with higher rigidity than the resin used to form the protrusions 5.

[0091] Specifically, the plate portion 2 preferably has a Young's modulus of 1 GPa or more, and more preferably 1.5 GPa or more. There is no particular upper limit to the Young's modulus, for example, it can be 1000 GPa or less.

[0092] From the viewpoint of inducing vibration modes effective for sound insulation in the sheet portion, the areal density of the sheet portion 2 is preferably 2.5 kg / m³. 2 The following is more preferably 2.0 kg / m2 From the viewpoint of operability of the sheet, 0.06 kg / m is preferred. 2 above.

[0093] Specific examples of materials constituting sheet 2 include polyacrylonitrile, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polyvinyl chloride, polyvinylidene chloride, polytrifluoroethylene, polyethylene, polypropylene, polystyrene, cyclic polyolefins, polynorbornene, polyethersulfone, polyetheretherketone, polyphenylene sulfide, polyarylate, polycarbonate, polyamide, polyimide, triacetyl cellulose, epoxy resin, acrylic resin, or oxazine resin, etc., or composite materials containing metals such as aluminum, stainless steel, iron, copper, zinc, or brass, inorganic glass, or inorganic particles or fibers, etc., but are not particularly limited to these. Among these, polyethylene terephthalate is preferred from the viewpoints of sound insulation, rigidity, formability, and cost.

[0094] The sheet 2 can be composed of one layer, or it can be composed of two or more layers. In the case of two or more layers, unless otherwise specified, the conditions of the sheet 2 in this specification are assumed to be the conditions of the laminate.

[0095] The thickness d of the sheet portion 2 is preferably 30 μm or more and 500 μm or less, more preferably 40 μm or more and 400 μm or less, and even more preferably 45 μm or more and 300 μm or less. If the thickness of the sheet portion 2 is 30 μm or more, the operability is excellent, and if it is 500 μm or less, the sound insulation performance improved by providing the protrusion 5 can be achieved.

[0096] From the viewpoint of preventing incident sound from reaching the sound insulation target area without passing through the convex and concave sheet members, the area of ​​sheet 2 needs to be equal to or greater than the area of ​​the sound insulation target area.

[0097] The shape of the piece 2 is not limited to Figure 1 and Figure 2 As shown, the surface of the convex and concave sheet member 1 can be appropriately set according to its orientation. For example, it can be a flat sheet, a curved sheet, or a special shape processed with curved surfaces, bends, etc. Furthermore, from the viewpoint of lightweighting, notches, punched portions, etc., can also be provided at any part of the sheet 2.

[0098] When the sheet 2 is used to be pasted onto the flexible member 8, it may also have an adhesive layer on any one or both sides 2a and 2b of the sheet 2.

[0099] Furthermore, there are no particular limitations on the manufacturing method of the sheet portion 2 and the protrusion portion 5. As described later, they can be used by bonding after being molded as different materials, or they can be used by integral molding. However, when they are used by bonding after being molded as different materials, an adhesive layer can be provided in the bonding portion of the sheet portion 2 with the protrusion portion 5 and / or the bonding portion of the protrusion portion 5 with the sheet portion 2.

[0100] The protrusions 5 constituting the concave-convex structure 3 impart local (preferably local and periodic) rigidity and mass to the plate 2. By imparting local rigidity and mass (preferably periodically), it functions to excite vibration modes corresponding to the distance between the plate 2 and the protrusion when sound waves are incident from the sound source.

[0101] The sound insulation mechanism described in patent documents 3 and 4, which uses a sound-insulating sheet with multiple cylindrical protrusions, is believed to be due to the dynamic mass increasing as each protrusion resonates in response to a specific frequency of sound wave when sound waves are incident. On the other hand, the vibration of the sheet portion 2 of the concave-convex sheet member 1 is considered to function as the sound insulation mechanism. That is, by imparting local (preferably local and periodic) rigidity and mass to the sheet portion 2, the protrusion 5 can excite a vibration mode corresponding to the distance between the protrusions, and the vibration of the sheet portion 2 can achieve a sound insulation effect at a specific frequency.

[0102] Depending on the thickness of the sheet and the mass of the protrusion, the shape of the concave-convex structure 3 is not limited to a linear shape. By setting the protrusion as a cylindrical or dot-shaped part, local (preferably local and periodic) rigidity and mass can be effectively imparted.

[0103] The method for forming the concave-convex structure 3 is not particularly limited. It can be formed by deforming the sheet portion 2. For example, it can be formed by pressing a mold with a cavity having a concave-convex structure onto a sheet without a concave-convex structure to deform it. Alternatively, it can be formed by using a material different from the sheet portion 2 to make the protrusion 5 and integrally forming it with the sheet portion 2. For example, it can be formed by flowing raw material into a cavity with a concave-convex structure. Alternatively, it can be formed by bonding the protrusion and the sheet portion with an adhesive material after they are made separately. Furthermore, the concave-convex structure 3 can be formed on one side of the sheet portion 2, or it can be formed on multiple sides. However, from the viewpoint of obtaining stable sound insulation, the inventors presume that it is preferable to form it on one side of the sheet portion 2.

[0104] Furthermore, the cross-sectional shape of the protrusion 5, which is orthogonal to the arrangement direction, can be approximately square, rectangular, trapezoidal, semi-circular, semi-elliptical, etc. From the perspectives of sound insulation performance, manufacturing cost, and operability, the cross-sectional shape of the protrusion 5 can be appropriately selected according to the application.

[0105] The maximum width of the cross section orthogonal to the arrangement direction of the concave-convex unit shape 4, i.e., the maximum width w1max of the cross section of the protrusion 5, is preferably 0.5 mm or more and 10 mm or less, more preferably 0.7 mm or more and 8 mm or less, and even more preferably 1 mm or more and 6 mm or less. If it is within the above range, a thin, lightweight concave-convex sheet member 1 with excellent sound insulation performance in the low frequency band can be obtained.

[0106] The height t of the concave-convex unit shape 4, i.e., the height t of the protrusion 5, is preferably 0.5 mm or more and 10 mm or less, more preferably 0.7 mm or more and 8 mm or less, and even more preferably 1 mm or more and 6 mm or less. If it is within the above range, a thin, lightweight concave-convex sheet member 1 with excellent sound insulation performance in the low frequency band can be obtained.

[0107] The spacing of the concave-convex unit shape 4, i.e. the width (w2) of the concave portion 6, is preferably 3 mm or more and 100 mm or less, more preferably 4 mm or more and 80 mm or less, and even more preferably 5 mm or more and 50 mm or less. If it is within the above range, a lightweight concave-convex sheet member 1 with excellent low-frequency sound insulation performance can be obtained.

[0108] In the sound insulation structure 7 constructed above, from the viewpoint that a high sound insulation effect can be obtained even for sound waves with low sound pressure, the concave-convex sheet member 1 preferably has a sheet portion 2 and a protrusion 5 that protrudes linearly on the sheet portion 2. The concave-convex unit shape having the protrusion 5 and the concave portion 6 along the protrusion 5 is formed by repeatedly arranging the sheet portion 2 in one or two directions.

[0109] Furthermore, when the specific gravity of the protrusion 5 is set to sg, it is preferable that the maximum width w1max (mm) of the cross-section of the protrusion 5, the height t (mm) of the protrusion 5, and the width w2 (mm) of the recess 6 are within the range specified by the following formulas (I) and (II) to form the concave-convex structure 3.

[0110] 0.1≤w1max×t×sg / w2≤10...(I)

[0111] 5≤w1max×t≤50...(II)

[0112] During the fabrication of the convex-concave sheet member 1, as described above, the optimal configuration of the convex-concave unit shape 4, which yields high sound insulation performance, varies depending on the relationship between the thickness d of the sheet portion 2 and the size of the protrusion 5 and the concave portion 6. However, as long as it falls within the range specified by the above formula (I) for the areal density of the convex-concave unit shape 4 and the above formula (II) for the cross-sectional area of ​​the protrusion 5, the convex-concave sheet member 1 can achieve good sound insulation. If the value is less than the lower limit of the range specified by the two formulas, the sound insulation strength decreases; if the value is greater than the upper limit, sound insulation performance in the low-frequency band region cannot be obtained.

[0113] The weight ratio of the protrusion 5 to the plate 2, expressed as (weight of the protrusion 5 / weight of the plate 2), is preferably in the range of 0.1 or more and 50 or less, more preferably 0.5 or more and 30 or less, and even more preferably 0.7 or more. Particularly preferred is 1.0 or more and 20 or less. Most preferably is 2.0 or more. By setting the weight ratio of the protrusion 5 to the plate 2 within this range, the vibration of the protrusion 5 relative to the plate 2 functions more effectively as a local (preferably local and periodic) rigidity and mass, thus effectively improving the sound insulation strength in the low-frequency band.

[0114] By subjecting the flexible component with the attached tabs to a load of 160 kPa or less with a deformation rate of 4% in a compression test using a compression testing machine, sufficient sound insulation can be achieved without suppressing the specific vibration of the tabs.

[0115] When the weight ratio of the protrusion to the sheet, expressed as (weight of protrusion 5 / weight of sheet 2), is 5 or less, it is more important not to suppress the vibration of the convex-concave sheet member. Therefore, it is preferable to apply a load of 10 kPa or less with a deformation rate of 4% in the compression test using a compression testing machine.

[0116] The area ratio of the protrusion 5 to the concave portion 6, expressed as (area of ​​the protrusion 5 / area of ​​the concave portion 6), is preferably in the range of 0.1 or more and 3 or less, more preferably 0.15 or more and 2 or less. More preferably, it is 0.2 or more and 1.5 or less. By setting the area ratio within this range, the protrusion 5 functions more effectively as a local rigidity and mass relative to the vibration of the sheet portion 2, thus effectively improving the sound insulation strength in the low-frequency band. It should be noted that the area of ​​the protrusion refers to the area occupied by the protrusion relative to the entire sheet portion, and the area of ​​the concave portion refers to the area occupied by the concave portion relative to the entire sheet portion.

[0117] like Figure 1 and Figure 2 As shown, the protrusion 5 can be composed of a single structure, or it can be as follows: Figure 3 As shown, it is composed of a composite structure, which consists of a base 5a protruding to an appropriate height and a counterweight 5b supported by the upper end of the base 5a and having a mass greater than that of the base 5a. Furthermore, as... Figure 4 As shown, the protrusion 5 can also be composed of a composite structure in which the counterweight 5b is embedded within the base 5a. In such a composite structure, the local rigidity and mass of the protrusion 5 are increased, resulting in improved low-frequency sound insulation of the concave-convex tab member 1. Alternatively, the protrusion 5 can also be a porous material containing pores (air or other gases) within a range that does not lead to a reduction in sound insulation.

[0118] The material constituting the base 5a can be the same as the material of the protrusion described later.

[0119] The material constituting the counterweight 5b can be appropriately selected considering factors such as quality and cost. For example, it can be a metal or alloy such as aluminum, stainless steel, iron, tungsten, gold, silver, copper, lead, zinc, or brass; an inorganic glass such as sodium glass, quartz glass, or lead glass; or a composite material in which powders of these metals or alloys or these inorganic glasses are included in the resin material of the base 5a. The material, mass, and specific gravity of the counterweight 5b can be determined in a manner consistent with the desired sound insulation frequency range of the sound insulation structure 7.

[0120] The protrusion 5 can also be a discontinuous structure that is appropriately interrupted in the middle of its length direction. In addition, multiple protrusions 5 can be arranged in parallel, but not only in parallel configuration, but can also have appropriate angles within a range where the protrusions 5 do not overlap each other.

[0121] In addition, such as Figure 5 As shown, the concave-convex structure 3 can also be configured such that rib-shaped protrusions 22 are provided on the surface 2a of the plate portion 2 of the concave-convex sheet member 1. The rib-shaped protrusions 22 are arranged in pairs, sandwiching the protrusions 5 at the edges of opposite shorter sides of the plate portion 2. The two rib-shaped protrusions 22 are configured to have their upper surfaces parallel to (or substantially parallel to) the surface 2a, and to extend in a rectangular plate shape parallel to (or substantially parallel to) the protrusions 5. The rib-shaped protrusions 22 have a maximum height that is higher than the maximum height of the protrusions 5 relative to the normal direction of the plate portion 2. In the case where the sheet portion 2 is cut from a strip of sheet material having a raised / lower structure 3 on one side, and manufactured by a so-called roll-to-roll process, by setting the axial direction (long side direction) of the rib-shaped protrusion 22 to the long side direction (sheet flow direction) of the sheet material, the rib-shaped protrusion 22 functions as a spacer even when the raised / lower sheet member 1 is wound into a sheet or overlapped in multiple sheets, thus suppressing contact between the protrusion 5 and the back side of the overlapping sheet portion 2. By providing the rib-shaped protrusion 22, manufacturing defects such as deformation, variation, cracking, detachment, and breakage of the protrusion 5 are less likely to occur, and the raised / lower sheet member 1 can be easily manufactured and stored by a so-called roll-to-roll process.

[0122] As the concave-convex tab member 1 constituting the sound insulation structure 7, it can be used Figures 1-5 The convex-concave sheet member with a linear concave-convex structure 3 as shown, or Figures 6-8 The convex-concave sheet component shown has a concave-convex structure 3 composed of dot-shaped protrusions.

[0123] Figures 6-8 The convex-concave sheet member 1 shown has multiple dot-shaped protrusions (in) on one side surface 2a of the sheet portion 2. Figures 6-8 In the description, it is also referred to as "protrusion" 51 as a protruding structure 3 formed by multiple protruding units arranged longitudinally and laterally at predetermined intervals in the shape of concave and convex units 4.

[0124] The protrusions 51 constituting the above-mentioned concave-convex structure 3 serve to (preferably periodically) impart local rigidity and mass, and to excite vibration modes corresponding to the distance between the plate 2 and the protrusions 51, thereby achieving high sound insulation performance exceeding the mass law when a sound wave of a specific frequency is incident.

[0125] like Figure 6 As shown, the protrusion 51 can be composed of a single structure, or it can be composed of a composite structure having a counterweight (not shown) if there are no forming problems caused by the placement of the counterweight. Alternatively, the protrusion 51 can also be a porous material.

[0126] In addition, such as Figure 7 As shown, the plate member 1 can also be configured with rib-shaped protrusions 22 on the surface 2a of the plate portion 2. The rib-shaped protrusions 22 are not limited to a rectangular plate shape. For example, as shown... Figure 8 As shown, the ribbed protrusions 23 can also be cylindrical, shaped generally cylindrical, and arranged in multiple rows at intervals on both sides of the edge in the first direction, respectively, along the second direction. By adopting this configuration, it is possible to obtain... Figure 7 The rectangular plate-shaped rib-like protrusions 22 shown have the same function and effect, and the multiple rib-like protrusions 23 arranged at intervals can improve the conformability (flexibility) of the convex-concave sheet member 1. Therefore, even for bonding surfaces with more complex shapes, the stretchable and flexible sheet 2 can conform to its surface shape.

[0127] The concave-convex structure 3 has protrusions 51 in the shape of concave-convex units, and the protrusions 51 are repeatedly arranged in at least two different directions along the surface 2a of the sheet portion 2 on the side of the concave-convex structure 3. Figures 6-8 In the substrate 2, which is rectangular in shape when viewed from above, there are protrusions 51 arranged along the orthogonal sides. The protrusions 51 can be roughly cylindrical, prismatic, conical, frustum conical, pyramidal, frustum pyramidal, hemispherical, ellipsoidal, etc., and they can be appropriately selected according to the application from the perspective of sound insulation performance, manufacturing cost, operability, etc.

[0128] In the aforementioned uneven structure 3, the ratio of the area of ​​the protrusion 51 to the area of ​​the surface 2a of the sheet portion 2 on the uneven structure 3 side is preferably 5% to 80% (5% or more and 80% or less), more preferably 5.5% to 70% (5.5% or more and 70% or less), and even more preferably 6% to 60% (6% or more and 60% or less). If the above ratio is within the above range, the sound insulation performance caused by the vibration of the sheet portion 2 is significantly improved. The area of ​​the protrusion 51 refers to the cross-sectional area of ​​the protrusion 51 at the location where it connects with the surface 2a of the sheet portion 2, which is parallel to the surface of the sheet.

[0129] Preferably, the mass of each (per unit) protrusion 51 in the aforementioned concave-convex structure 3 is 20 mg or more and 900 mg or less, and the ratio (fill rate) of the area of ​​the protrusion 51 to the area of ​​the surface 2a is within the aforementioned range. In this case, the protrusion 51 serves to impart local (preferably local and periodic) rigidity and mass to the plate 2 in a mode effective for sound insulation when sound waves are incident from the noise source.

[0130] As described above, the mass of each unit shape of the protrusion 51 is preferably 20 mg or more and 900 mg or less, more preferably 22 mg or more and 700 mg or less, even more preferably 24 mg or more and 600 mg or less, and particularly preferably 25 mg or more and 500 mg or less. If the mass of each unit shape of the protrusion 51 is 20 mg or more and 900 mg or less, then by imparting local (preferably local and periodic) rigidity and mass, a vibration mode effective for sound insulation at a specific frequency can be excited in the plate 2, and the sound insulation performance is improved dramatically.

[0131] From the viewpoint of inducing vibration modes that are effective for sound insulation in the sheet portion, the density of the protrusion 51 is preferably 100 kg / m³. 3 The above is further optimized to be 1000 kg / m 3 The above. From a lightweight perspective, 10000 kg / m² is preferred. 3 Below, it is usually 8000 kg / m 3 The following can be 5000 kg / m 3 The following can also be 3000 kg / m 3 the following.

[0132] Furthermore, the maximum width of the protrusion 51 in a cross-section parallel to surface 2a (hereinafter referred to as "maximum width"), i.e., the diameter when the protrusion 51 is cylindrical, and the maximum span when the protrusion 51 is prismatic, is preferably 0.5 mm or more and 50 mm or less, more preferably 1.0 mm or more and 30 mm or less, even more preferably 1.5 mm or more and 20 mm or less, and particularly preferably 2.0 mm or more and 10 mm or less. If the maximum width of the protrusion 51 is 0.5 mm or more, the sound insulation performance is excellent; if it is 50 mm or less, the formability and operability are excellent.

[0133] Furthermore, the height (maximum height) of the protrusion 51 is preferably 0.1 mm or more, 0.5 mm or more and 50 mm or less, more preferably 0.7 mm or more and 30 mm or less, even more preferably 0.9 mm or more and 20 mm or less, and particularly preferably 1.2 mm or more and 10 mm or less. If the height of the protrusion 51 is 0.5 mm or more, the sound insulation performance is excellent; if it is 50 mm or less, the formability and operability are excellent.

[0134] Furthermore, the spacing of the protrusions 51 is preferably 1 mm or more and 100 mm or less, more preferably 1.4 mm or more and 80 mm or less, even more preferably 1.8 mm or more and 60 mm or less, and particularly preferably 2 mm or more and 50 mm or less. When the spacing of the concave-convex unit shapes is 1 mm or more, the formability is excellent; when it is 100 mm or less, the sound insulation performance is excellent. The spacing of the concave-convex unit shapes refers to the distance (configuration spacing) between the center of the concave-convex unit shape and the center of the adjacent concave-convex unit shape when connected by a straight line.

[0135] The mass of each protrusion 51 relative to the thickness of the sheet 2 (mass of each protrusion (mg / piece) / thickness of the sheet 2 (μm)) is preferably in the range of 0.4 or more and 4 or less. When the protrusion 51 has a certain weight relative to the thickness of the substrate 2, it is possible to effectively impart local (preferably local and periodic) rigidity and mass, thereby improving the sound insulation effect.

[0136] The number (ratio) of protrusions 51 per unit area is preferably multiple, specifically, preferably 40 per m. 2 More than 1,000,000 per m 2 The following is more preferably 100 pieces / m 2 More than 500,000 per m 2 The following is a further preferred configuration: 300 units / m 2 More than 100,000 per m 2 The following is particularly preferred: 500 pieces / m 2 More than 30,000 per m 2 Below, 1000 pieces / m 2 More than 10,000 per m 2 The following describes how the presence of a certain number of protrusions 51 effectively reduces sound insulation.

[0137] There are no particular limitations on the type of material used in forming the protrusion 5. Preferably, it is a material with rubber elasticity that can be measured for dynamic viscoelasticity, such as resin or elastomer. It should be noted that the above description is for the material of the sheet 2, but it can also be applied to the materials used in forming the protrusion 5 as described below.

[0138] Examples of resins include thermosetting or photocurable resins and thermoplastic resins; examples of elastomers include thermosetting or photocurable elastomers and thermoplastic elastomers. Photocurable resins or photocurable elastomers are preferred, especially from the perspective of good shape transferability and excellent sound insulation performance. When thermosetting or thermoplastic resins or thermosetting or thermoplastic elastomers are used as the material for the protrusion 5, a heat-based curing reaction is required during the molding of the protrusion 5, thus there is a strong tendency for air bubbles to form in the molded protrusion 5. When air bubbles are formed, the sound insulation performance decreases. On the other hand, when photocurable resins or photocurable elastomers are used as the material for the protrusion 5, the aforementioned air bubble problem does not occur, and therefore, a decrease in sound insulation performance is less likely.

[0139] Resins and elastomers can be used alone or in any combination and ratio of two or more materials. From the point of view, it is preferable to combine two or more materials to control properties such as storage modulus and tensile elongation at break.

[0140] Examples of resins used in forming the protrusion 5 include thermosetting resins such as unsaturated polyester resins, phenolic resins, epoxy resins, polyurethane resins, or rosin-modified maleic acid resins; photocurable resins such as homopolymers or copolymers of monomers such as epoxy (meth)acrylates, urethane (meth)acrylates, polyester (meth)acrylates, polyether (meth)acrylates, or their modifiers; and thermoplastic resins such as homopolymers and copolymers of vinyl monomers such as vinyl acetate, vinyl chloride, vinyl alcohol, vinyl butyral, or vinylpyrrolidone, or saturated polyester resins, polycarbonate resins, polyamide resins, polyolefin resins, polyaryl ester resins, polysulfone resins, or polyphenylene ether resins. Among these, urethane (meth)acrylates, polyester (meth)acrylates, or polyether (meth)acrylates with low elastic modulus of cured products are preferred, and urethane (meth)acrylates are particularly preferred.

[0141] Examples of elastomers used to form the protrusion 5 include: vulcanized rubbers such as chemically cross-linked natural or synthetic rubber; thermosetting elastomers such as thermosetting resin elastomers such as polyurethane rubber, silicone rubber, fluororubber, or acrylic rubber; thermoplastic elastomers such as olefin-based thermoplastic elastomers, styrene-based thermoplastic elastomers, vinyl chloride-based thermoplastic elastomers, urethane-based thermoplastic elastomers, ester-based thermoplastic elastomers, amide-based thermoplastic elastomers, silicone rubber-based thermoplastic elastomers, or acrylic thermoplastic elastomers; photocurable elastomers such as acrylic photocurable elastomers, silicone photocurable elastomers, or epoxy photocurable elastomers; silicone thermosetting elastomers; acrylic thermosetting elastomers; and epoxy thermosetting elastomers. Preferably, silicone thermosetting elastomers, acrylic thermosetting elastomers, acrylic photocurable elastomers, or silicone photocurable elastomers are used as thermosetting elastomers.

[0142] Photocurable resins refer to resins that polymerize through light irradiation. Examples include photoradical polymers and photocationic polymers. Photoradical polymers are preferred. These resins preferably have at least one (meth)acryloyl group within their molecule. While not particularly limited to photoradical polymers having one or more (meth)acryloyl groups within their molecule, examples of photoradical polymers can be listed from the viewpoint of the elastic modulus of the cured product, such as methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, tert-butyl methacrylate, 2-methylbutyl methacrylate, n-pentyl methacrylate, n-hexyl methacrylate, n-heptyl methacrylate, and 2-methylhexyl methacrylate. 2-Ethylhexyl acrylate, 2-Butylhexyl (meth)acrylate, Isooctyl (meth)acrylate, Isoamyl (meth)acrylate, Isononyl (meth)acrylate, Isodecyl (meth)acrylate, Isobornyl (meth)acrylate, Cyclohexyl (meth)acrylate, Benzyl (meth)acrylate, Phenoxy (meth)acrylate, Nonyl (meth)acrylate, Decyl (meth)acrylate, Lauryl (meth)acrylate, Hexadecyl (meth)acrylate, Stearyl (meth)acrylate, Morpholin-4-yl (meth)acrylate, or urethane (meth)acrylate, etc. Among these, urethane (meth)acrylate is preferred from the viewpoint of the elastic modulus of the cured product.

[0143] Additionally, the resin used to form the protrusion 5 may also contain compounds having olefinically unsaturated bonds. Examples of compounds having olefinically unsaturated bonds include aromatic vinyl monomers such as styrene, α-methylstyrene, α-chlorostyrene, vinyltoluene, or divinylbenzene; vinyl ester monomers such as vinyl acetate, vinyl butyrate, N-vinylformamide, N-vinylacetamide, N-vinyl-2-pyrrolidone, N-vinylcaprolactam, or divinyl adipate; vinyl ethers such as ethyl vinyl ether or phenyl vinyl ether; allyl compounds such as diallyl phthalate, trimethylolpropane diallyl ether, or allyl glycidyl ether; (meth)acrylamide, N,N-dimethyl(meth)acrylamide, N-hydroxymethyl(meth)acrylamide, N-methoxymethyl... Methacrylamide, N-butoxymethacrylamide, N-tert-butylmethacrylamide, methacryloylmorpholine, or methylenebis(methacrylamide) and other methacrylamides; methyl methacrylate, ethyl methacrylate, propyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, tert-butyl methacrylate, hexyl methacrylate, 2-ethylhexyl methacrylate, lauryl methacrylate, stearyl methacrylate, tetrahydrofurfuryl methacrylate, morpholine methacrylate, 2-hydroxyethyl methacrylate, methacrylic acid... Mono(meth)acrylates such as 2-hydroxypropyl acrylate, 4-hydroxybutyl acrylate, glycidyl acrylate, dimethylaminoethyl acrylate, diethylaminoethyl acrylate, benzyl acrylate, cyclohexyl acrylate, phenoxyethyl acrylate, tricyclodecane acrylate, dicyclopentenyl acrylate, allyl acrylate, 2-ethoxyethyl acrylate, isobornyl acrylate, or phenyl acrylate; ethylene glycol dimethacrylate, diethylene glycol dimethacrylate, triethylene glycol dimethacrylate, dimethacrylate. Tetraethylene glycol ester, polyethylene glycol di(meth)acrylate (repeating units: 5–14), propylene glycol di(meth)acrylate, dipropylene glycol di(meth)acrylate, tripropylene glycol di(meth)acrylate, tetrapropylene glycol di(meth)acrylate, polyethylene glycol di(meth)acrylate (repeating units: 5–14), 1,3-butanediol di(meth)acrylate, 1,4-butanediol di(meth)acrylate, polyethylene glycol di(meth)acrylate (repeating units: 3–16), poly(1-methylbutanediol) di(meth)acrylate (repeating units: 5–20), 1,6-hexanediol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate9-Nonyl glycol ester, neopentyl glycol di(meth)acrylate, neopentyl glycol di(meth)acrylate of hydroxypentanoic acid, di(meth)acrylate of dicyclopentanediol, caprolactone adduct of neopentyl glycol hydroxypentanoic acid (n+m=2-5) in di(meth)acrylate, γ-butyrolactone adduct of neopentyl glycol hydroxypentanoic acid (n+m=2-5) in di(meth)acrylate, caprolactone adduct of neopentyl glycol (n+m=2-5) in di(meth)acrylate, caprolactone adduct of butanediol (n+m=2-5) in di(meth)acrylate, caprolactone adduct of cyclohexanediol... Di(meth)acrylates of ester adducts (n+m=2-5), di(meth)acrylates of caprolactone adducts of dicyclopentanediol (n+m=2-5), di(meth)acrylates of caprolactone adducts of bisphenol A (n+m=2-5), di(meth)acrylates of caprolactone adducts of bisphenol F (n+m=2-5), di(meth)acrylates of ethylene oxide adducts of bisphenol A (p=1-7), di(meth)acrylates of propylene oxide adducts of bisphenol A (p=1-7), di(meth)acrylates of ethylene oxide adducts of bisphenol F (p=1-7), and so on. Di(meth)acrylates of phenol F propylene oxide adducts (p=1–7), trimethylolpropane tri(meth)acrylates, trimethylolpropane ethylene oxide adducts (p=1–5) tri(meth)acrylates, trimethylolpropane propylene oxide adducts (p=1–5) tri(meth)acrylates, glyceryl tri(meth)acrylates, glyceryl ethylene oxide adducts (p=1–5) tri(meth)acrylates, bis(trimethylolpropane) tetra(meth)acrylates, bis(trimethylolpropane) ethylene oxide adducts (p=1–5) tetra(meth)acrylates, pentaerythritol tri(meth)acrylates Acrylic esters, pentaerythritol tetra(meth)acrylate, pentaerythritol ethylene oxide adduct (p=1–5) tri(meth)acrylate, pentaerythritol ethylene oxide adduct (p=1–15) tetra(meth)acrylate, pentaerythritol propylene oxide adduct (p=1–5) tri(meth)acrylate, pentaerythritol propylene oxide adduct (p=1–15) tetra(meth)acrylate, dipentaerythritol ethylene oxide adduct (p=1–5) penta(meth)acrylate, dipentaerythritol ethylene oxide adduct (p=1–15) hexa(meth)acrylate, N,N',N”-tris((meth)acryloyloxy poly(p=1-4)(ethoxy)ethyl)isocyanurate and other poly(meth)acrylates, tri(meth)acrylates of pentaerythritol caprolactone (4-8 mol) adduct, tetra(meth)acrylates of pentaerythritol caprolactone (4-8 mol) adduct, dipentaerythritol penta(meth)acrylate, dipentaerythritol hexa(meth)acrylate, penta(meth)acrylates of dipentaerythritol caprolactone (4-12 mol) adduct, hexa(meth)acrylates of dipentaerythritol caprolactone (4-12 mol) adduct, N,N',N”-tris(acryloyloxyethyl)isocyanurate, N,N'-bis(acryloyloxyethyl)-N”-hydroxyethyl isocyanurate, ethylene oxide-modified (meth)acrylates of isocyanurate, propylene oxide-modified (meth)acrylates of isocyanurate. Or, polyfunctional (meth)acrylates such as ethylene oxide-propylene oxide modified (meth)acrylates with isocyanurate; or epoxy poly(meth)acrylates obtained by the addition reaction of polyepoxy compounds with multiple epoxy groups in the molecule, such as bisphenol A glycidyl ether, bisphenol F glycidyl ether, phenolic varnish epoxy resin, cresol phenolic varnish epoxy resin, pentaerythritol polyglycidyl ether, trimethylolpropane triglycidyl ether, or triglycidyl tri(2-hydroxyethyl)isocyanurate, with (meth)acrylic acid. Among these, phenoxyethyl acrylate, benzyl acrylate, 2-ethylhexyl (meth)acrylate, and methoxy polyethylene glycol acrylate with low elastic modulus of the cured product are preferred, and 2-ethylhexyl (meth)acrylate or methoxy polyethylene glycol acrylate are more preferred. These can be used alone or in combination of two or more.

[0144] The content of resin and / or elastomer used in the formation of the protrusion 5 can be appropriately adjusted from the viewpoint of sound insulation performance, manufacturing cost, other functions, etc., and is not particularly limited. When the mass of the material constituting the protrusion 5 is set to 100% by mass, it is typically 70% by mass or more, preferably 80% by mass or more. Alternatively, it can be 100% by mass, preferably 99% by mass or less.

[0145] When the protrusion 5 is formed using a photocurable resin or elastomer, from the viewpoint of improving formability, mechanical strength, and reducing manufacturing costs, it is preferable to include a photopolymerization initiator. Examples of such initiators include benzoin-based, acetophenone-based, thioxanthone-based, phosphine oxide-based, or peroxide-based photopolymerization initiators. Specific examples of such photopolymerization initiators include benzophenone, 4,4-bis(diethylamino)benzophenone, 2,4,6-trimethylbenzophenone, methyl benzoylbenzoate, 4-phenylbenzophenone, tert-butylanthraquinone, 2-ethylanthraquinone, diethoxyacetophenone, 2-hydroxy-2-methyl-1-phenylpropane-1-one, 2-hydroxy-1-{4-[4-(2-hydroxy-2-methyl-propanoyl)-benzyl]phenyl}-2-methyl-propane-1-one, benzoin dimethyl ketal, 1-hydroxycyclohexyl- Phenylacetonate, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin isobutyl ether, 2-methyl-[4-(methylthio)phenyl]-2-morpholino-1-propanone, 2-benzyl-2-dimethylamino-1-(4-morpholinophenyl)-butanone-1, diethylthioxanone, isopropylthioxanone, 2,4,6-trimethylbenzoyl diphenylphosphine oxide, bis(2,6-dimethoxybenzoyl)-2,4,4-trimethylpentylphosphine oxide, bis(2,4,6-trimethylbenzoyl)-phenylphosphine oxide, or methyl benzoylformate, etc. These materials can be used alone or in any combination and ratio with two or more materials.

[0146] The content of the photopolymerization initiator in the resin used to form the protrusion 5 is not particularly limited. From the viewpoint of improving mechanical strength and maintaining an appropriate reaction rate, when the mass of the material constituting the uneven structure 3 is set to 100% by mass, it is generally 0.1% by mass or more, preferably 0.3% by mass or more, and more preferably 0.5% by mass or more. In addition, it is generally 3% by mass or less, preferably 2% by mass or less.

[0147] To improve sound insulation and other functions, the resin used in forming the protrusion 5 may also include particles, plates, spheres, etc. These materials are not particularly limited and can include metals, inorganic or organic materials. From the viewpoint of improving mechanical strength and reducing material costs, the protrusion 5 may contain inorganic microparticles. For example, transparent inorganic microparticles such as silicon dioxide, alumina, titanium dioxide, soda glass, or diamond can be used. In addition to such inorganic microparticles, resin particles such as acrylic resin, styrene resin, silicone resin, melamine resin, epoxy resin, or copolymers thereof can also be used as microparticles.

[0148] The resin used in the formation of the protrusion 5 may contain various additives such as flame retardants, antioxidants, plasticizers, defoamers, or release agents as other components, as long as they do not impede the sound insulation performance. They may be used alone or in combination of two or more.

[0149] Flame retardants are additives formulated to make flammable raw materials difficult to burn or prevent ignition. Specific examples include bromine compounds such as pentabromodiphenyl ether, octabromodiphenyl ether, decabromodiphenyl ether, tetrabromobisphenol A, hexabromocyclododecane or hexabromobenzene, phosphorus compounds such as triphenyl phosphate, chlorine compounds such as chlorinated paraffin, antimony compounds such as antimony trioxide, metal hydroxides such as aluminum hydroxide, nitrogen compounds such as melamine cyanurate, or boron compounds such as sodium borate, but are not particularly limited to these.

[0150] In addition, antioxidants are additives formulated to prevent oxidative degradation. Specific examples include phenolic antioxidants, sulfur-based antioxidants, or phosphorus-based antioxidants, but they are not particularly limited to these.

[0151] Plasticizers are additives formulated to improve softness and weather resistance. Specific examples include phthalates, adipates, trimellitates, polyesters, phosphate esters, citrates, sebacic acid esters, azelaic acid esters, maleic acid esters, silicone oils, mineral oils, vegetable oils, or their modified forms, but are not particularly limited to these.

[0152] (Forming method of concave-convex sheet components)

[0153] There are no particular limitations on the forming method of the convex-concave sheet component 1; any generally known sheet forming method can be used. In the case of thermosetting or thermoplastic resins or elastomers, examples include melt molding such as compression molding, extrusion molding, and injection molding. In this case, the molding conditions such as temperature and pressure can be appropriately varied depending on the type of material used. Alternatively, in the case of photocurable resins or elastomers, for example, these resins can be injected into a plate-shaped mold that transmits active energy rays, and then photocured by irradiation with active energy rays.

[0154] The active energy rays used for curing photocurable resins, etc., are any rays that cure the photocurable resin, etc., and examples include ultraviolet light and electron beams. The amount of irradiation by the active energy rays is simply the amount required to cure the photocurable resin, etc., and is determined by the type and amount of monomer and polymerization initiator; for example, irradiation with ultraviolet light of wavelength 200-400 nm is typically performed in the range of 0.1-200 J. As the light source for the active energy rays, chemical lamps, xenon lamps, low-pressure mercury lamps, high-pressure mercury lamps, or metal halide lamps can be used. Furthermore, irradiation by the active energy rays can be performed in one stage, but to obtain photocurable resin sheets with good surface properties, multi-stage or at least two-stage irradiation is preferred. Additionally, when using a photocurable resin, a curing accelerator may be included.

[0155] Furthermore, there are no particular limitations on the method of forming the protrusion 5 on the sheet portion 2. It can be a method of simultaneously forming the sheet portion 2 and the protrusion 5 using a mold with a cavity having a concave-convex structure, or it can be a method of forming by combining the sheet portion 2 and the protrusion 5. The following describes in detail the method of forming by combining the sheet portion 2 and the protrusion 5, but it is not limited to this method.

[0156] The method of combining the sheet portion 2 and the protrusion 5 is not particularly limited. It can be any method, such as forming the protrusion 5 on the sheet portion 2 or bonding the formed protrusion 5 to the sheet portion 2. In the case of bonding, an adhesive is preferred, but the type of adhesive is not limited as long as it can bond the protrusion 5 to the sheet portion 2.

[0157] Next, an example of a method for molding the convex-concave sheet component 1 using thermosetting resin will be described. Figure 11 The schematic cut-off end face of a mold used to form an example of a convex-concave sheet member 1 is shown. The mold 16 shown in the figure has a plurality of cavities (grooves) 16a formed on its upper surface such that the surface is recessed into a groove shape corresponding to the shape of the convex-concave structure 3 of the convex-concave sheet member 1, that is, corresponding to the shape of the convex part 5.

[0158] The mold 16 can be used to form the convex-concave sheet component 1 according to the following steps. First, the mold 16 is positioned with the side having the cavities 16a facing upwards, and a photocurable resin is allowed to flow into and fill each cavity 16a. A sheet portion 2, made of a material that transmits specific light such as ultraviolet light or electron beams that cures the photocurable resin, is then superimposed on it. Next, with the sheet portion 2 pressed against the upper surface of the mold 16, specific light is irradiated from above, causing the photocurable resin within the cavities 16a to cure through the sheet portion 2 and fix it to the surface of the sheet portion 2. Furthermore, if the photocurable resin cures, then... Figure 12 As shown, by peeling the sheet portion 2 on which the protrusion 5 is fixed on the surface from the mold 16, a convex-concave sheet member 1 with a convex-concave structure 3 formed on the surface of the sheet portion 2 can be obtained.

[0159] Figure 13 This refers to a method of forming a raised / concave sheet member 1 by using a strip-shaped sheet portion 2, which is also made of a light-curing resin and a material that transmits specific light during the curing of the resin, through a so-called roll-to-roll process. For example... Figure 13 As shown in (A), in this molding process, a cylindrical roller-shaped mold 17 is used, which has multiple cavities 17a formed circumferentially on its circumferential surface such that the surface is recessed into grooves corresponding to the shape of the aforementioned protrusion 5. The long strip-shaped sheet portion 2 is fed out from a sheet supply unit that supports and feeds the sheet portion 2 from a master roll wound with the sheet portion 2 (not shown), as... Figure 13As shown in (B), under tension applied by the pressing rollers 18 and 19 respectively disposed on the upstream and downstream sides of the conveyor, the sheet portion 2 is pressed and wound around the circumference of the mold 17, and the sheet portion 2 that has passed through the pressing roller 19 is wound up by a sheet winding unit (not shown). A nozzle 20 for supplying photocurable resin is disposed above the pressing roller 18, such that the resin supplied from the nozzle 20 flows into and fills the cavity 17a of the mold 17. Multiple light sources 21 for irradiating specific light are disposed below the mold 17, such that the photocurable resin filled in the cavity 17a is irradiated with specific light through the sheet portion 2 and cured. It should be noted that the mold 17 is configured to rotate synchronously with the sheet conveying speed of the sheet supply unit and the sheet winding unit.

[0160] In this method, the embossed sheet component 1 can be formed according to the following steps. First, the front end of the elongated sheet portion 2 is extracted from the sheet supply unit and wound around the circumference of the mold 17, and tension is applied while it is wound around the pressing rollers 18 and 19. The front end of the sheet portion 2 is then mounted on the sheet winding unit. Next, the sheet portion 2 is supplied from the sheet supply unit, and while being wound by the sheet winding unit, the sheet portion 2 is wound around the rotating mold 17. At the same time, photocurable resin flows out from the nozzle 20 and fills the cavity 17a of the mold 17 with photocurable resin. As the sheet portion 2 wound around the mold 17 rotates and moves towards the pressing roller 19 together with the mold 17, a specific light source 21 located below the mold 17 illuminates the surface of the sheet portion 2. The specific light illuminates the photocurable resin in the cavity 17a through the sheet portion 2, thereby curing and fixing the photocurable resin to the surface of the sheet portion 2. The conveying speed (rotation speed of mold 17) of the sheet portion 2 wound around mold 17 is set to the degree to which the photocurable resin in cavity 17a is fully cured by receiving specific light irradiated from light source 21 during the period when sheet portion 2 is wound around mold 17. Then, sheet portion 2 is peeled from mold 17 by pressing roller 19, and sheet portion 2 with protrusions 5 fixed on its surface is wound into sheet winding unit, thereby continuously forming a strip of convex-concave sheet member 1. The wound sheet portion 2 is cut into dimensions corresponding to the setting position, thereby obtaining a convex-concave sheet member 1 of the desired size with convex-concave structure 3 formed on the surface of sheet portion 2. Since the cavities 16a and 17a formed in the above molds 16 and 17 are formed in a linear shape along the outer shape of protrusions 5, the resin flows in evenly along the cavities 16a and 17a, and air bubbles are less likely to enter the cavities 16a and 17a with the resin.

[0161] In the above Figures 11-13When manufacturing the convex-concave sheet member 1 in the manner described above, a convex-shaped member can be provided on the sheet supplied to the roller, or a member with a concave-convex structure can be provided on the sheet supplied to the roller. In the former case, the manufactured convex-concave sheet member 1 has a structure consisting of a sheet portion 2 formed by the sheet supplied to the roller and a convex portion 5 formed by roll-to-roll; in the latter case, it has a structure consisting of a sheet portion 2 comprising two layers—the sheet supplied to the roller and the sheet formed by roll-to-roll—and a convex portion 5 formed by roll-to-roll. Furthermore, in this manner, for example, the material of the sheet supplied to the roller can be the material described in the description of the sheet portion, and the material of the sheet formed by roll-to-roll and / or the convex portion can be the material described in the description of the convex portion.

[0162] [Soft components]

[0163] The sound insulation structure 7 has a flexible member 8. The flexible member 8 is disposed on the bonded body 9 and is sandwiched between the bonded body 9 and the tab member 1. The shape of the flexible member 8 is not particularly limited as long as it can be disposed between the tab member 1 and the bonded body, but it is preferably sheet-like.

[0164] Regarding the method of providing the flexible member 8 to the bonded body 9, as described above, an adhesive layer or the like can be provided between the convex and concave sheet member 1 and the flexible member 8. Alternatively, the convex and concave sheet member 1 can be attached to the flexible member 8 using an adhesive, bonding agent, double-sided tape, or paper tape, or physically fixed to the flexible member 8 using a riveting machine or stapler. Since the convex and concave sheet member is bonded to the flexible member using an adhesive layer, no other structure is needed to maintain the structure, which is therefore preferable. Furthermore, from the viewpoint of adhesive strength, the storage modulus of the adhesive layer is preferably 0.05 MPa or higher. Additionally, even without fixation, they can be in a tightly fitted state. Furthermore, the orientation of the convex and concave surfaces of the convex and concave sheet member 1 can be located on the flexible member side, and the flexible member 8 can be disposed on the 2a and 2b surfaces of the sheet portion of the convex and concave sheet member 1.

[0165] The flexible member 8 is disposed at least between the convex-concave sheet member 1 and the bonded body 9 to function in a way that prevents the vibration of the sheet portion 2 in the convex-concave sheet member 1 from being hindered due to contact with the bonded body 9. As the flexible member 8, from the viewpoint that it does not hinder the vibration of the sheet portion 2 even when in contact with it, it is preferable to use a material that is easily deformable and can follow the vibration displacement of the sheet portion. Specifically, from the viewpoint that a high sound insulation effect can be obtained even for sound waves with low sound pressure, the flexible member 8 is subjected to a load of 4% deformation rate of 160 kPa or less in the compression test, and more preferably 120 kPa or less. As long as this value is met, there is no particular limitation on its material. For example, glass wool, rock wool, felt, rubber cloth or non-woven fabric, fibrous sound-absorbing materials made of polymers or inorganic fibers, polyurethane, various rubbers, polymer foams such as polyethylene, polystyrene or polypropylene, inorganic porous materials, metal foams, or porous materials formed by curing their pulverized parts or fiber scraps with various adhesives can be used. They can be used alone or in combination. From the viewpoint of achieving high sound insulation even for sound waves with relatively low sound pressure levels, the preferred materials are non-woven fabrics, polymer foams, or metal foams, as well as glass wool, felt, or rubber sheeting, with non-woven fabrics or foams being particularly preferred. These materials can be used individually or in any combination of two or more.

[0166] Furthermore, from the viewpoint of not hindering the vibration of the convex-concave plate member, the flexible member is preferably as flexible as described above. On the other hand, from the viewpoint of maintaining the strength of the structure, the load imparted in the compression test with a deformation rate of 4% is preferably 0.15 kPa or more. This is because it is not necessary to maintain the strength of other components by making the flexible member strong, and therefore it is preferred from the viewpoint of installation and manufacturing.

[0167] The compression test described above was conducted according to the following method.

[0168] Compression tests are performed to determine the hardness of soft components using a compression testing machine (e.g., Brookfield CT3-4500 Compression Testing Machine Texture Analyzer). A cylindrical acrylic probe with a diameter of 12.7 mm and a height of 35 mm is used, perpendicular to the thickness direction of the soft component, to apply a load at a speed of 0.1 mm / s, and the deformation rate and load are measured. The surface of the soft component to which the load is applied is formed to be a flat surface with a larger area than the bottom surface of the cylindrical probe.

[0169] From the viewpoint of not hindering the vibration of the sheet portion of the convex and concave sheet member and suppressing the enlargement of its size, the thickness of the flexible member 8 is preferably 0.2 μm or more and 100 mm or less, more preferably 0.5 μm or more and 50 mm or less, and even more preferably 1 μm or more and 30 mm or less.

[0170] [Substrate]

[0171] The sound insulation structure 7 has an adhesive body 9 on which the aforementioned flexible member 8 is disposed (bonded). The adhesive body 9 is disposed on the side of the flexible member 8 opposite to the side where the tab member 1 is located.

[0172] The raw materials constituting the bonded body 9 are not particularly limited as long as they can support the flexible member 8 on which the tab member 1 is provided.

[0173] Specific examples of raw materials constituting the bonded body 9 include polyacrylonitrile, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polyvinyl chloride, polyvinylidene chloride, polytrifluoroethylene, polyethylene, polypropylene, polystyrene, cyclic polyolefins, polynorbornene, polyethersulfone, polyetheretherketone, polyphenylene sulfide, polyarylate, polycarbonate, polyamide, polyimide, triacetyl cellulose, polystyrene, epoxy resin, acrylic resin or oxazine resin, and other organic materials, or composite materials containing metals such as aluminum, stainless steel, iron, copper, zinc or brass, inorganic glass, inorganic particles or fibers, etc., but are not particularly limited to these. From the viewpoints of sound insulation, rigidity, formability and cost, the bonded body 9 is preferably selected from at least one of the group consisting of light-curable resin sheets, thermosetting resin sheets, thermoplastic resin sheets, metal plates or alloy plates.

[0174] The thickness and areal density of the bonded body 9 are not particularly limited. From the perspectives of sound insulation performance, rigidity, formability, lightweight, and cost, the thickness is generally preferably 0.01 mm or more and 50 mm or less, more preferably 0.05 mm or more and 25 mm or less, and even more preferably 0.1 mm or more and 10 mm or less. In addition, the areal density is preferably 2.0 kg / m³. 2 The following is a further preferred value of 1.5 kg / m 2 Below that, it is typically 0.5 kg / m 2 above.

[0175] The advantage of this invention is that it achieves high sound insulation even when the convex-concave tab member 1 is placed on a rigid component. For example, this effect can be achieved even with a bonded body having a Young's modulus of 1 GPa or higher. There is no particular upper limit to the Young's modulus; for example, it can be 1000 GPa or lower.

[0176] It should be noted that the shape of the bonded body 9 can be appropriately set according to the surface on which the flexible component 8 is set, and there is no particular limitation. For example, it can be a flat sheet, a curved sheet, or a special shape processed with curved surfaces, bends, etc. Furthermore, from the viewpoint of lightweighting, it is also possible to provide notches, die-cut sections, etc.

[0177] [Other Components]

[0178] Within the scope of achieving the effects of the present invention, the sound insulation structure 7 may also include components other than the aforementioned convex-concave sheet member 1, flexible member 8, and bonded body 9 (other components), such as heat-insulating materials, non-combustible materials, etc. Other components may be disposed between the convex-concave sheet member 1 and the flexible member 8, etc.

[0179] Another embodiment of the present invention is a sound insulation sheet, which is a sound insulation sheet having at least a concave-convex sheet member and a flexible member, specifically having:

[0180] A convex-concave sheet member having a convex-concave structure, the convex-concave structure having a sheet portion and a plurality of protrusions disposed on the surface of the sheet portion; and

[0181] A flexible component is provided on the aforementioned convex and concave sheet component.

[0182] In the compression test conducted using a compression testing machine, the aforementioned soft components were subjected to a load of 160 kPa or less with a deformation rate of 4%.

[0183] The weight ratio of the protrusion to the plate in the aforementioned convex-concave plate member, expressed as (weight of the protrusion / weight of the plate), is 0.7 or more.

[0184] In this specification, a sound insulation sheet refers to a component having concave and convex sheet components and flexible components.

[0185] The conditions and characteristics of the sound insulation sheet, the components constituting the sound insulation sheet, and other components in this embodiment can be applied in the same way to the conditions and characteristics of the sound insulation sheet component, the components constituting the sound insulation sheet component, and other components in the sound insulation structure described above. That is, the sound insulation sheet of this embodiment can be processed as a sound insulation sheet after removing the bonded element from the sound insulation structure described above. It should be noted that the sound insulation sheet of this embodiment may also include the bonded element described above. In this case, the sound insulation structure can be configured as follows: a bonded element having the aforementioned flexible member disposed between the bonded element and the convex-concave sheet component.

[0186] <2. Manufacturing method of sound insulation structure>

[0187] The manufacturing method of the sound insulation structure 7 is not particularly limited. For example, it can be manufactured by bonding the flexible member 8 to the side of the convex-concave sheet member 1 that does not have the convex-concave structure 3 with an adhesive or the like, and then bonding the bonded body to the side of the flexible member 8 that is opposite to the bonding surface of the convex-concave sheet member 1 with an adhesive or the like.

[0188] The convex-concave sheet component 1 can be manufactured by: molding the convex portion 5 and the sheet portion 2 separately and then bonding them together with an adhesive or the like; or by integrally molding the convex portion 5 and the sheet portion 2 using a mold with a cavity having a convex-concave structure 3. The flexible component 8 can be manufactured by known methods, or commercially available products can be used.

[0189] Furthermore, during the molding of the embossed member 1, by curing the resin or the like, which is the raw material of the embossed member 1, in a state of contact with the flexible member, the embossed member 1 and the flexible member 8 can be bonded without the use of adhesives or other bonding materials.

[0190] <3. Characteristics of Sound Insulation Structures>

[0191] [Sound insulation properties]

[0192] To evaluate the sound insulation properties of the sound insulation structure, sound transmission loss was measured. The conditions for measuring sound transmission loss are shown below.

[0193] When white noise is generated in one of two spaces divided by a soundproof structure, the sound transmission loss (TL) is calculated based on the following equation (1) at each center frequency of the 1 / 12 octave band from 72.8 Hz to 10900 Hz, according to the difference between the sound pressure level at a predetermined location in the white noise generating space (sound source room) and the sound pressure level at a predetermined location in the other space (sound receiving room).

[0194] [Number 1]

[0195] TL[dB]=L in -L out -3…(1)

[0196] Lin: Sound pressure level (dB) in the sound source chamber

[0197] Lout: Sound pressure level (dB) in the receiving chamber

[0198] Incident sound: White noise (e.g., an average sound pressure level of about 0.94 Pa in the frequency range of 72.8–10900 Hz)

[0199] Sample-microphone distance: 10mm

[0200] The sound insulation structure 7 preferably satisfies the conditions represented by the following formulas (A) to (C). Satisfaction of the following conditions indicates that a high sound insulation effect can be obtained by arranging the sound insulation structure in the desired orientation.

[0201] (TL1-TL2)-(TL3-TL4)>3dB...(A)

[0202] TL1-TL2>0dB...(B)

[0203] TL3-TL4>0dB...(C)

[0204] TL1 (dB): Sound transmission loss of the sound insulation structure when the concave-convex tab member is positioned with its side facing the sound source.

[0205] TL2 (dB): The sound transmission loss of a sound insulation structure when the uneven sheet is replaced with a flat sheet of the same mass and area, under the condition of TL1.

[0206] TL3 (dB): Sound transmission loss of the sound insulation structure when the bonded side faces the sound source.

[0207] TL4 (dB): The sound transmission loss of a sound insulation structure when the uneven sheet is replaced with a flat sheet of the same mass and area, under the condition of TL3.

[0208] The aforementioned TL1 and TL2 are the acoustic transmission losses at the frequencies where TL1-TL2 is at its maximum, and the aforementioned TL3 and TL4 are the acoustic transmission losses at the frequencies where TL3-TL4 is at its maximum.

[0209] It should be noted that, typically, the frequency at which TL1-TL2 reaches its maximum is the frequency of the peak value (maximum value of the peak) in a graph obtained with frequency as the horizontal axis and TL1-TL2 as the vertical axis. Similarly, the frequency at which TL3-TL4 reaches its maximum is the frequency of the peak value (maximum value of the peak) in a graph obtained with frequency as the horizontal axis and TL3-TL4 as the vertical axis. In this embodiment, the peak values ​​refer to these peak values.

[0210] When the conditions of formulas (A) to (C) above are met, from the viewpoint of increasing the improvement effect of sound insulation performance obtained by controlling the setting orientation of the sound insulation structure, the value of the left side of formula (A) above is preferably greater than 3, more preferably greater than 4, further preferably greater than 5, particularly preferably greater than 7, further particularly preferably greater than 8, and most preferably greater than 10. As a method to meet the above formula (A), for example, the following method can be listed: For a convex-concave sheet member consisting of rectangular convex portions 5 of urethane acrylate strips arranged in one direction with a width of 6 mm, a height of 5 mm, and a spacing of 20 mm on a PET substrate with a thickness of 250 μm, the edges of the convex-concave sheet member are attached to ultrafine acrylonitrile fiber XAI (registered trademark) (unit area weight 1000 g / m²) using double-sided tape. 2 (25mm thick) The opposite sides of the convex and concave sheet components are glued to the surface of the bonded body 9, which is made of steel plate with a thickness of 0.6mm, to make a sound insulation structure.

[0211] Satisfying the conditions in equations (A) to (C) above indicates that a high sound insulation effect can be obtained by setting the sound insulation structure in the desired orientation. Furthermore, by applying this technology to conventional sound insulation components, improvements in the sound insulation characteristics obtained from conventional sound insulation components can be expected.

[0212] Example

[0213] The present invention will now be described in more detail through embodiments, but the invention is not limited to these embodiments as long as it does not depart from its spirit. It should be noted that the values ​​of various conditions and evaluation results in the embodiments represent the preferred scope of the invention in the same way as the preferred scope in the above embodiments. The preferred scope of the invention can be determined by considering the preferred scope in the above embodiments and the range represented by the values ​​of the following embodiments or combinations of values ​​of the embodiments.

[0214] [Example 1]

[0215] By mass ratio, each raw material was measured in the following manner: EBECRYL230 (manufactured by Daicel-Allnex Co., Ltd., urethane acrylate, weight average molecular weight Mw: 5000) / Aronix M-120 (manufactured by Toa Synthetic Co., Ltd., special acrylate) / IRGACURE 184 (manufactured by BASF, 1-hydroxycyclohexylphenyl ketone) / IRGACURE.TPO (manufactured by BASF, 2,4,6-trimethylbenzoyl diphenylphosphine oxide) = 50 / 50 / 1 / 0.1. The mixture BL was obtained by stirring for 20 minutes and then degassing for 10 minutes using a degassing mixer (manufactured by THINKY, AR-250).

[0216] like Figures 11-13 As shown, the above mixture BL flows into an A4-sized mold 16, which is made of aluminum and has grooves (cavities) arranged at 20mm intervals in one direction. A layer with a thickness of 250μm, a Young's modulus of approximately 4GPa, a specific gravity of 1.4, and a surface density of 0.175kg / m³ is then placed on the mold. 2 The PET film is used as the material for sheet 2, and a high-pressure mercury lamp 21 is used with a wavelength of 200nm~450nm and an energy of 1000mJ / m 2 The embossed component 1 is formed by curing with ultraviolet light. Then, the embossed component 1, which has been cured inside the mold, is peeled off from the mold.

[0217] The obtained concave-convex plate component 1 and Figure 1The convex-concave sheet component shown is roughly the same, consisting of a 0.05 mm thick film formed by curing the above-mentioned mixture BL on a 250 μm thick PET film, and then having rectangular protrusions 5 arranged in one direction along a 6 mm wide, 5 mm high, and 20 mm spaced apart.

[0218] For the convex-concave tab component 1, double-sided tape is used to adhere each edge of the convex-concave tab component 1 to the surface made of ultra-fine acrylonitrile fiber XAI (registered trademark) (unit area weight 1000g / m²). 2 A sound insulation structure is created by attaching the opposite sides of the flexible component 8 (25mm thick) to the surface 8a of a bonded body 9 made of a steel plate with a thickness of 0.6mm. Here, as... Figure 9 As shown, a sound insulation structure 7 is defined as a sound insulation structure arranged in the order of overlapping the convex-concave sheet member 1, the flexible member 8, and the bonded body 9, as viewed from the sound source 10. Additionally, as... Figure 10 As shown, the sound insulation structure 11 is configured such that the bonding body 9, the flexible component 8, and the convex and concave sheet component 1 are stacked in the order of stacking when viewed from the sound source 10.

[0219] [Example 2]

[0220] Except for changing the spacing between the concave and convex parts of the convex and concave sheet component 1 to 30mm, the sound insulation structures 7 and 11 are manufactured in the same manner as in Example 1.

[0221] [Example 3]

[0222] Except for replacing the flexible component 8 with a 10mm thick polyurethane foam, the sound insulation structures 7 and 11 were fabricated in the same manner as in Example 1.

[0223] [Example 4]

[0224] Except for replacing the flexible component 8 with 12.5 mm thick crystalline alumina fiber MAFTEC (registered trademark), the sound insulation structures 7 and 11 were manufactured in the same manner as in Example 1.

[0225] [Example 5]

[0226] Except for replacing the flexible component 8 with 20mm thick expanded polystyrene foam, the sound insulation structures 7 and 11 were fabricated in the same manner as in Example 1.

[0227] [Example 6]

[0228] The surface of the concave-convex structure 3 of the concave-convex plate component 1 is changed to the side of the flexible component 8, so that... Figure 9 The method shown becomes Figure 14The sound insulation structures 7 and 11 are fabricated in the same manner as in Example 1, except that they are not fabricated in the manner shown.

[0229] [Example 7]

[0230] The thickness of the PET film in the embossed sheet component 1 was changed from 250 μm to 125 μm, and the embossed structure 3 was changed from a linear embossed structure with a width of 6 mm, a height of 5 mm, and a spacing of 20 mm to an embossed structure with a spacing of 18 mm composed of cylindrical protrusions with a diameter of 6 mm and a height of 5 mm. Figure 6 The dotted uneven structure shown is used to fabricate sound insulation structures 7 and 11 in the same manner as in Example 1.

[0231] [Comparative Example 1]

[0232] Except for replacing the flexible component 8 with an acrylic sheet with a thickness of 4 mm, the sound insulation structures 7 and 11 are manufactured in the same manner as in Example 1.

[0233] [Measurement of Acoustic Transmission Loss]

[0234] Sound transmission loss was measured using the sound insulation structures fabricated in Examples 1-6 and Comparative Example 1. The differences were summarized in Tables 1-1 and 1-2 below, using the measured values ​​when the uneven sheet member 1 of each sound insulation structure was replaced with a flat sheet of the same quality. In Tables 1-1 and 1-2, the "peak value (dB) of the difference in transmission loss between the uneven sheet and the flat sheet of the same quality" for the case where the member on the sound wave incident side is an uneven sheet represents "TL1-TL2" in equations (A)-(C) above. Furthermore, the "peak value (dB) of the difference in transmission loss between the uneven sheet and the flat sheet of the same quality" for the case where the member on the sound wave incident side is an adhesive body represents "TL3-TL4" in equations (A)-(C) above.

[0235] The conditions for measuring acoustic transmission loss are shown below.

[0236] When white noise is generated in one of the two spaces divided by the sound insulation structure made in Examples 1 to 6 and Comparative Example 1, the sound transmission loss (TL) is calculated based on the following formula (1) at each center frequency of the 1 / 12 octave band of 72.8 Hz to 10900 Hz, according to the difference between the sound pressure level at a predetermined location in the space (sound source room) where white noise is generated and the sound pressure level at a predetermined location in the other space (sound receiving room).

[0237] [Number 2]

[0238] TL[dB]=L in -L out -3…(1)

[0239] Lin: Sound pressure level (dB) in the sound source chamber

[0240] Lout: Sound pressure level (dB) in the receiving chamber

[0241] Incident sound: white noise (average sound pressure level of 0.94 Pa in the frequency range of 72.8–10900 Hz)

[0242] Sample-microphone distance: 10mm

[0243] Compression test

[0244] To determine the hardness of various soft components using a CT3-4500 compression testing machine / texture analyzer (Brookfield), compression tests were performed. A cylindrical acrylic probe with a diameter of 12.7 mm and a height of 35 mm was used, perpendicular to the thickness direction of the soft component, to apply a load at a speed of 0.1 mm / s, and the deformation rate and load were measured. The loaded surface of the soft component was formed to be larger and flatter than the bottom surface of the cylindrical probe.

[0245] Table 2 summarizes the loads (kPa) applied to various soft components at a deformation rate of 4%.

[0246] In addition, “flexible member” in Tables 1-1 and 1-2 means a flexible member or a member that exists in the same location as the flexible member (i.e., an acrylic sheet in Comparative Example 1).

[0247] [Table 1-1]

[0248]

[0249] [Table 1-2]

[0250]

[0251] [Table 2]

[0252]

[0253] As shown in Table 1 above, it can be seen from Examples 1 to 7 that the sound insulation structure stacked with sound waves incident from the side of the raised sheet has higher sound insulation performance in the sound insulation band of the raised sheet compared to the sound insulation structure stacked with sound waves incident from the side of the bonded body. Furthermore, as shown in Table 2 above, it can be seen that in Comparative Example 1, compared to Examples 1 to 7, a rigid member with high rigidity and low deformability was used as a flexible member. By hindering the vibration of the raised sheet portion, the sound insulation performance near the sound insulation band of the raised sheet was significantly reduced, regardless of the stacking order. Based on the above, it can be confirmed that in a sound insulation structure using a member with low rigidity that can follow the vibration of the raised sheet portion as a flexible member and stacked in a manner where incident sound sequentially penetrates the raised sheet, the flexible member, and the bonded body, the sound insulation performance in the sound insulation band of the raised sheet is improved.

[0254] [Reference Example]

[0255] [simulation]

[0256] The raised and recessed structure of piece 2 was reproduced in the simulation software COMSOL Multiphysics (registered trademark). Figure 1 or Figure 6 Using unit cells of roughly the same shape, an infinite planar model with periodic boundary conditions was constructed. The physical properties of the plates and protrusions are shown in Tables 3 below for models 1 to 41. Furthermore, a 0.05 mm thick film of photocurable resin is present on the surface of the plate where the protrusions are located, and protrusions made of photocurable resin with a density of 1050 kg / m³ are disposed on this film. 2 The Poisson's ratio is 0.49 and the loss factor is 0.1. The elastic modulus of the photocurable resin is calculated using the following formula (3).

[0257] [Number 2]

[0258]

[0259] E: Elastic modulus of light-cured resin (Pa)

[0260] f: Frequency (Hz)

[0261] Sound transmission loss simulations were performed on the sound insulation structures with shapes 1 to 41 in Table 3 below. The simulated sound transmission loss values ​​for the convex / concave plates of each shape were compared with the mass law values ​​when the convex / concave plates of each shape were replaced with flat plates of the same mass and area as the plate portion without any convex / concave features. In this case, the weight ratio of the convex portion to the plate portion was set as the horizontal axis, and the peak value of the difference obtained by subtracting the mass law value from the sound transmission loss value when using convex / concave plates was calculated. The graph with this value set as the vertical axis is shown below. Figure 15 As shown.

[0262] The results show that excellent sound insulation can be obtained by making the weight ratio of the protrusion to the sheet preferably 0.7 or more, and more preferably 2.0 or more. It should be noted that the same tendency is also shown in the case where the flexible member described in one of the embodiments is provided, regarding the relationship between the peak value of the difference and the weight ratio of the protrusion to the sheet.

[0263] [Table 3]

[0264]

[0265] Symbol Explanation

[0266] 1: Concave-convex plate component

[0267] 2: Film Department

[0268] 2a, 2b: The surface of the sheet

[0269] 3: Concave-convex structure

[0270] 4: Shape of concave and convex units

[0271] 5, 51: convex part

[0272] 5a: Base

[0273] 5b: Counterweight

[0274] 6: concave part

[0275] 7, 11: Sound insulation structure

[0276] 8: Soft components

[0277] 8a, 8b: Surfaces of flexible components

[0278] 9: Adhesive

[0279] 10: Sound source

[0280] 16, 17: Molds

[0281] 16a, 17a: Cavity

[0282] 18, 19: Crimping rollers

[0283] 20: Nozzle

[0284] 21: Light source

[0285] 22: Rib-like protrusions

[0286] 23: Rib-like protrusions.

Claims

1. A sound insulation structure, comprising: For soft components, in compression tests conducted using a compression testing machine, a load of 4% or less is applied with a deformation rate of 160 kPa or less; The bonded body, which is provided with the flexible component; The plate portion has a Young's modulus of over 1 GPa; and A protrusion is provided on the surface of the sheet portion; The sheet portion and the protrusion constitute a convex-concave sheet component, which has a convex-concave structure formed by the protrusion being disposed on the surface of the sheet portion. The flexible member is disposed between the bonded body and the tab member.

2. The sound insulation structure according to claim 1, wherein the weight ratio of the convex portion to the sheet portion of the concave-convex sheet member, expressed as the weight of the convex portion / weight of the sheet portion, is 0.7 or more.

3. The sound insulation structure according to claim 2, wherein an adhesive layer is provided between the convex and concave sheet components and the flexible components.

4. The sound insulation structure according to claim 2 or 3, wherein the areal density of the sheet portion is 2.5 kg / m³. 2 the following.

5. The sound insulation structure according to claim 2 or 3, wherein the density of the protrusion is 100 kg / m³. 3 above.

6. The sound insulation structure according to claim 2 or 3, wherein the height of the protrusion is 0.1 mm or more.

7. The sound insulation structure according to claim 2 or 3, wherein the number ratio of the protrusions is 1000 to 10000 per m. 2 .

8. The sound insulation structure according to claim 2 or 3, wherein the load imparting a deformation rate of 4% in the compression test using a compression testing machine is 0.15 kPa or more.

9. The sound insulation structure according to claim 2 or 3, wherein the weight ratio of the convex portion to the plate portion of the convex-concave plate member, expressed as the weight of the convex portion / weight of the plate portion, is 5 or less, and, In the compression test conducted using a compression testing machine, the soft component is subjected to a load of 10 kPa or less with a deformation rate of 4%.

10. The sound insulation structure according to claim 2 or 3, wherein the concave-convex structure of the concave-convex sheet member is disposed on the side of the flexible member or the opposite side thereof.

11. The sound insulation structure according to claim 2 or 3, used with a sound source, wherein the tab member is disposed with its side facing the sound source.

12. The sound insulation structure according to claim 2 or 3, which simultaneously satisfies the conditions represented by the following formulas (A) to (C), (TL1-TL2)-(TL3-TL4)>3dB ...(A) TL1-TL2>0dB ...(B) TL3-TL4>0dB ...(C) TL1: Sound transmission loss of a sound insulation structure when the concave-convex tab member is positioned with its side facing the sound source. TL2: Under the conditions of TL1, the sound transmission loss of the sound insulation structure when the uneven sheet is replaced with a flat sheet of the same mass and area. TL3: Sound transmittance of the sound insulation structure when the bonded side faces the sound source. TL4: Under the conditions of TL3, the sound transmission loss of the sound insulation structure when the uneven sheet is replaced with a flat sheet of the same mass and area. TL1 and TL2 are the acoustic transmission losses at the frequencies where TL1-TL2 are at their maximum, and TL3 and TL4 are the acoustic transmission losses at the frequencies where TL3-TL4 are at their maximum.

13. The sound insulation structure according to claim 2 or 3, wherein the convex-concave sheet member has a sheet portion and a protrusion protruding linearly on the sheet portion, and the convex-concave unit shape having the protrusion and a concave portion along the protrusion is repeatedly arranged on the sheet portion in one or two directions.

14. The sound insulation structure according to claim 1, wherein the material of the flexible component is non-woven fabric, foam, glass wool, felt, or rubber sheet.

15. The sound insulation structure according to claim 2 or 3, wherein the flexible component is nonwoven fabric.

16. The sound insulation structure according to claim 2 or 3, wherein the flexible component is a foam.

17. A sound insulation sheet, comprising: film department; A plurality of protrusions are provided on the surface of the sheet portion; and Soft components The sheet portion and the protrusion constitute a convex-concave sheet component, which has a convex-concave structure formed by providing a plurality of protrusions on the surface of the sheet portion, and the flexible member is disposed on the convex-concave sheet component. In the compression test conducted using a compression testing machine, the soft component was subjected to a load of 4% deformation rate of less than 160 kPa. The weight ratio of the convex portion to the plate portion, expressed as the weight of the convex portion / weight of the plate portion, of the concave-convex plate member is 0.7 or more. The plate has a Young's modulus of more than 1 GPa.

Images